Mercury MerCruiser 4.3 TKS User Manual Download

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Section 5 - Maintenance

Page 80

90-899883179 OCTOBER 2007

Gearcase Anodic Plate

‑ Mounted on the underside of the lower gearcase.

6205

Alpha, Bravo One, Bravo Two Models

All Bravo Three Models

a -

Anode

Ventilation Plate Anode

‑ Mounted on the front of the gearcase.

6122

5639

a -

Anode

Drive Mounted Anodic Block (if equipped)

‑ Mounted to underside of gimbal housing.

5640

MerCathode System

‑ Electrode assembly replaces Anodic block. System should be

tested to ensure adequate output. The test should be performed where boat is moored,

using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury

MerCruiser dealer.

Summary of Contents for MerCruiser 4.3 TKS

Page 1: ...x II ISO 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with the m...

Page 2: ...rinting Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring ob...

Page 3: ...me in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the eng...

Page 4: ...er is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and...

Page 5: ...rbureted Engines 21 Audio Warning System 23 Testing The Audio Warning System 24 Section 3 On The Water Safe Boating Suggestions 26 Be Alert to Carbon Monoxide Poisoning 27 Good Ventilation 27 Poor Ven...

Page 6: ...Checking 53 Filling 54 Changing 55 Power Trim Fluid 57 Checking 57 Filling 57 Changing 58 Cleaning The Flame Arrestor 58 Positive Crankcase Ventilation Valve PCV 59 Changing 59 Changing the Water Sep...

Page 7: ...rter Motor Will Not Crank Engine Or Cranks Slow 108 Engine Will Not Start Or Is Hard To Start 108 Engine Runs Rough Misses or Backfires 108 Poor Performance 108 Excessive Engine Temperature 109 Insuff...

Page 8: ...Page iv 90 899883179 OCTOBER 2007...

Page 9: ...ury Product Protection Plan United States and Canada 3 Mercury MerCruiser Limited Warranty Gasoline Fueled Products Only 4 3 Year Limited Warranty Against Corrosion 6 Global Warranty Charts 7 Consumer...

Page 10: ...rned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine pro...

Page 11: ...g the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory a...

Page 12: ...ed installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 year...

Page 13: ...purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that c...

Page 14: ...t noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or...

Page 15: ...nds Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Coolin...

Page 16: ...year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japa...

Page 17: ...r 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 50...

Page 18: ...that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one 1 year of Mercury limited f...

Page 19: ...t SERIAL Engine Serial Number FAMILY Engine Family STD Emissions Standard D O M Date of Manufacture DISP Piston Displacement EMISSION CONTROL INFORMATION REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIF...

Page 20: ...Section 1 Warranty Notes Page 12 90 899883179 OCTOBER 2007...

Page 21: ...Bravo Sterndrive Serial Number and Identification 14 Bravo Transom Serial Number 15 Lanyard Stop Switch 16 Instrumentation 17 Remote Controls 18 Panel Mount Features 18 Console Mount Features 19 Powe...

Page 22: ...umbers and maintenance color codes decal The engine serial number is also stamped in the engine block Bravo Sterndrive Serial Number and Identification The sterndrive serial number gear ratio model nu...

Page 23: ...amped in the U bolt plate of the Bravo transom assembly 25904 a Bravo transom assembly U bolt plate a Transom assembly serial Number The serial number is also stamped on the gimbal housing This is use...

Page 24: ...is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of acci...

Page 25: ...rumentation typically found on some boats The owner operator should be familiar with all instruments and their functions Because of the large variety of instrumentation and manufacturers you should ha...

Page 26: ...e depressed only when the remote control handle is in the neutral position and should only be used to assist in starting the engine Lanyard Stop Switch Turns the ignition off whenever the operator whe...

Page 27: ...to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort required to move the remote control handle Refer to instructions provided with remote cont...

Page 28: ...terndrive unit down in can Help the boat accelerate and plane off quicker Generally improve the ride in choppy water In most cases reduce boat speed If in excess lower the bow of some boats to a point...

Page 29: ...a fuse will blow or the circuit breaker will trip open The cause must be found and corrected before replacing the fuse or resetting the circuit breaker NOTE In an emergency when the engine must be op...

Page 30: ...arness if an electrical overload occurs mc74907 1 3 A 15 amp accessory fuse is located on the rear of the engine This fuse protects the accessory circuits 7524 4 A 20 amp fuse may be located in the ig...

Page 31: ...Control Panel is further protected by a 20 amp in line fuse mc70527 1 7 The Quicksilver MerCathode System has a 20 amp in line fuse in the wire which connects to the positive terminal on controller I...

Page 32: ...If the warning horn emits a continuous beep do not operate the engine unless avoiding a hazardous situation If the alarm sounds stop the engine immediately Investigate cause and correct it if possibl...

Page 33: ...e Pump 31 Protecting People in the Water 31 While You Are Cruising 31 While Boat Is Stationary 31 High Speed and High Performance Operation 31 Passenger Safety in Pontoon Boats and Deck Boats 31 Boats...

Page 34: ...instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for signs of...

Page 35: ...similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight and never back...

Page 36: ...the boat is moored in a confined space b Mooring close to another boat with its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim...

Page 37: ...t cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation WARNING Explosive fumes contain...

Page 38: ...ckage was operating above idle RPM when the engine stopped 2 After the handle returns to the neutral idle position resume normal starting procedures Throttle Only Operation 1 Refer to Remote Controls...

Page 39: ...NING A spinning propeller a moving boat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine immediately whenever anyone in the water is near your boa...

Page 40: ...is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction in boat speed could result in the elevated passenger falling...

Page 41: ...Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward even out of th...

Page 42: ...on from impact damage under all conditions Operating with Low Water Inlets in Shallow Water mc75827 1 a a Low Water Inlets NOTICE Operating in shallow water can cause severe engine damage due to clogg...

Page 43: ...housing which allows exhaust gases to escape between propeller and gear housing Drive unit installed too high on transom Elevation and Climate Elevation and climate changes will affect the performance...

Page 44: ...e observed Do not operate below 1500 RPM for extended periods of time for the first 10 hours Shift into gear as soon as possible after starting and advance the throttle above 1500 rpm if conditions pe...

Page 45: ...ason of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operated continuously year round you...

Page 46: ...Section 3 On The Water Notes Page 38 90 899883179 OCTOBER 2007...

Page 47: ...39 Section 4 Specifications Table of Contents Fuel Requirements 40 Fuel Ratings 40 Using Reformulated Oxygenated Gasolines USA Only 40 Gasolines Containing Alcohol 40 Engine Oil 41 Engine Specificatio...

Page 48: ...alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse...

Page 49: ...he Mercury MerCruiser Full Synthetic 20W 40 oil is unavailable you can use the following lubricants listed in order of recommendation 1 Mercury Quicksilver 25W 40 Synthetic Blend NMMA FC W rated 4 cyc...

Page 50: ...bricant Bravo One 2736 mL 92 1 2 oz Bravo Two 3209 mL 108 1 2 oz Bravo Three single seawater pickup 2972 mL 100 1 2 oz Bravo Three dual seawater pickup 2736 mL 92 1 2 oz Engine IMPORTANT Your applicat...

Page 51: ...58 Cleaning The Flame Arrestor 58 Positive Crankcase Ventilation Valve PCV 59 Changing 59 Changing the Water Separating Fuel Filter 59 Lubrication 60 Steering System 60 Throttle Cable 62 Shift Cable...

Page 52: ...Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dea...

Page 53: ...engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immedia...

Page 54: ...ions are secure Clean the gauges If operating in saltwater reduce this interval to every 25 hours or 30 days whichever occurs first Scheduled Maintenance NOTE Only perform maintenance that applies to...

Page 55: ...the electrical system for loose damaged or corroded fasteners Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspec...

Page 56: ...cling of waste and contain and dispose of fluids as required Checking 1 Stop the engine Allow approximately 5 minutes for the oil to drain into the oil pan The boat must be at rest in the water 2 Remo...

Page 57: ...ury Full Synthetic MerCruiser Oil 20W 40 5 0 TKS 4 25 liters 4 5 U S qt 5 7 TKS Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be changed before pl...

Page 58: ...ard oil filter 2 Coat sealing ring on new filter with engine oil and install 3 Tighten oil filter securely following filter manufacturer s instructions Do not overtighten 4 Remove oil fill cap IMPORTA...

Page 59: ...r dealer Filling 1 Remove the fill cap dipstick and observe the level 2 Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid ATF to bring the fluid level up to the...

Page 60: ...until it seats on the filler neck 4 With the engine at normal operating temperature check the coolant level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks...

Page 61: ...1 Remove the fill cap from the coolant recovery bottle 2 Fill to the FULL line with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Coolin...

Page 62: ...ed models Closed cooled models a Gear lube monitor Filling IMPORTANT If more than 59 mL 2 fl oz of High Performance Gear Lubricant is required to fill the monitor a seal may be leaking Damage to the s...

Page 63: ...lube monitor 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Bravo One Models Remove the propeller lower the sterndrive unit to the full down in positi...

Page 64: ...r the sterndrive unit so that the propeller shaft is level Fill the sterndrive unit through the oil fill drain hole with specified gear lubricant until an air free stream of lubricant flows from oil v...

Page 65: ...ool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position...

Page 66: ...se ventilation hose from the fitting on the flame arrestor and valve cover 2 Remove the flame arrestor e d c a 16330 b a Locknut b Sealing washer c Typical carburetor d Crankcase ventilation hose e Fl...

Page 67: ...y switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and av...

Page 68: ...s continue stop the engine immediately and contact your authorized Mercury MerCruiser dealer Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious...

Page 69: ...eering pin mc71904 1 a a Steering pin Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin 92 883725K01 4 On dual engine boats Lubricate the tie bar...

Page 70: ...Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Shift Cable Typical 1 Lubricate the pivot points and the guide contact sur...

Page 71: ...aft lubrication refer to Propellers Sterndrive U joint Shaft Splines And O rings Sterndrive Unit Removed 1 Coat sterndrive U joint O rings and driveshaft splines with grease b a 8591 a Driveshaft spli...

Page 72: ...els The coupler and shaft splines can be lubricated without removing the sterndrive unit Apply lubricant from a typical hand operated grease gun until a small amount of grease begins to push out The P...

Page 73: ...n tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer drive sleeve propeller and thrust hub off propeller shaft Alpha Propeller Installation NOTICE Operating the en...

Page 74: ...own into spline washer Check propeller at least after 20 hours of operation Do not operate with loose propeller Bravo One Propeller Removal WARNING Rotating propellers can cause serious injury or deat...

Page 75: ...on Grease Propeller shaft 92 802867Q 1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859A1 3 Install Flo Torq II Drive Hub into propeller NOTE The drive sleeve is tapered and will slide...

Page 76: ...vent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer spline washer propeller and thrust hub off propeller shaft Bravo Two Prope...

Page 77: ...water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood...

Page 78: ...ngine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required m...

Page 79: ...Check propeller at least every 20 hours of operation and retorque as needed Description Nm lb in lb ft Aft propeller nut 81 60 8 Install the propeller shaft anode over the propeller shaft nut 9 Place...

Page 80: ...tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in the direction of belt length that join transverse cracks...

Page 81: ...O N E b a 14980 a Kent Moore Tension Gauge b Serpentine belt 7 While holding the adjustment stud at the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 16 mm 5 8 in locking nut b...

Page 82: ...tem or operating the engine Dual Water Pick up Flush Gearcase Seal Kit 91 881150K 1 9194 Blocks off the front water inlet holes on the dual water inlet gearcases Sterndrive Water Pickups There are two...

Page 83: ...s not a hose running to the transom refer to Alternative Water Pickups 4 If flushing the cooling system with the boat in the water a Raise sterndrive unit to trailer position b Install the appropriate...

Page 84: ...ith the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive unit and to the engine during...

Page 85: ...and overheat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply 9 Slowly advance throttle until engine reaches 1300 RPM 100 RPM 10 Observ...

Page 86: ...e assembly can damage components and lead to rapid corrosion Do not use any cleaning equipment such as brushes or high pressure washers to clean the MerCathode assembly 6211 c b a a MerCathode referen...

Page 87: ...ome models have a MerCathode System as standard equipment 8716 5 6 1 7 8 2 4 3 1 2 2 3 4 5 6 7 8 1 Gearcase anodic plate 2 Ventilation plate anode 3 Gimbal mounted anodic block 4 MerCathode System 5 A...

Page 88: ...e Anode Mounted on the front of the gearcase a 6122 a 5639 a Anode Drive Mounted Anodic Block if equipped Mounted to underside of gimbal housing 5640 MerCathode System Electrode assembly replaces Anod...

Page 89: ...that the MerCathode reference electrode is not damaged do not paint or pressure wash 6206 a b a MerCathode controller b MerCathode assembly Anode Kit if equipped Mounted to the boat transom 5642 Trim...

Page 90: ...be sprayed 3 All lubrication points especially steering system shift and throttle linkages should be kept well lubricated 4 Flush cooling system periodically preferably after each use Painting Your Po...

Page 91: ...ansom of the boat around these items b a 5578 a Painted boat transom b Unpainted Area on Transom 2 Painting Sterndrive Unit or Transom Assembly Sterndrive unit and transom assembly should be painted w...

Page 92: ...Section 5 Maintenance Notes Page 84 90 899883179 OCTOBER 2007...

Page 93: ...Single Point Drain System 89 Three Point Manual Drain System 90 Multi Point Drain MPD System 90 Air Actuated Single Point Drain System 91 Boat in the Water 91 Boat out of the Water 93 Manual Single P...

Page 94: ...eeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations Preparing Power Package for Storage 1 Fill the fuel...

Page 95: ...12 Store the battery according to the manufacturer s instructions ENGINE AND FUEL SYSTEM PREPARATION WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned...

Page 96: ...the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or close the seacock disconnect and plug the seawater inlet hose and ensure the bilge pump is o...

Page 97: ...d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators 21125 a b c d d Scorpion Models a Blue air pump b Air manifold c...

Page 98: ...HREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug MULTI POINT DRAIN MPD SYSTEM 10226 M110050 932356 72 b a a b 6129 a Side of cylinder block b Bottom of exhaust manifolds a b 6130 a Water circ...

Page 99: ...ter inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air p...

Page 100: ...t exchanger This must be removed within 30 seconds to properly vent the cooling system 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump...

Page 101: ...12 Remove the air pump from the air manifold and return it to the mounting bracket 13 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other...

Page 102: ...he fitting 8293 b d e a c a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from bo...

Page 103: ...ide drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 Crank the engine over slightly with starter motor to purge an...

Page 104: ...ock if equipped or remove and plug the water inlet hose 2 Rotate the blue handle counterclockwise until it stops approximately two turns The red on the handle shaft indicates that the drain system is...

Page 105: ...stat housing 7 Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug if removed The handle is fully seated when no red is visible Do not overtight...

Page 106: ...re that all water is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug The handle is fully seated when no red is visible Do not ov...

Page 107: ...sporting the boat or while performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump D...

Page 108: ...engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 6 Prior to launching the boat or starting the engine close the drain sys...

Page 109: ...on 6 Storage 90 899883179 OCTOBER 2007 Page 101 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equi...

Page 110: ...up pump Do not allow the engine to start 5 After the cooling system has been drained completely install the drain plugs reconnect the hoses and tighten all hose clamps securely BOAT IN THE WATER 1 Clo...

Page 111: ...on 6 Storage 90 899883179 OCTOBER 2007 Page 103 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equi...

Page 112: ...drain system by installing the blue drain plugs 6 Open the seacock if equipped or unplug and reconnect the water inlet hose before operating the engine Draining the Sterndrive NOTE This procedure is...

Page 113: ...wer Package Recommissioning 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Disconnecting or connecting the battery cables in the incorrect order can ca...

Page 114: ...Section 6 Storage Notes Page 106 90 899883179 OCTOBER 2007...

Page 115: ...Backfires 108 Poor Performance 108 Excessive Engine Temperature 109 Insufficient Engine Temperature 109 Low Engine Oil Pressure 109 Battery Will Not Recharge 109 Remote Control Is Difficult to Move H...

Page 116: ...ever to the 1 4 throttle position and attempt to restart Faulty ignition system component Service the ignition system Clogged fuel filter Replace fuel filter Stale or contaminated fuel Drain fuel tank...

Page 117: ...nspect and test pressure cap Faulty seawater pickup pump Repair Seawater discharge restricted or plugged Clean exhaust elbows Insufficient Engine Temperature Possible Cause Remedy Faulty thermostat Re...

Page 118: ...n Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized...

Page 119: ...ssistance 112 Local Repair Service 112 Service Away From Home 112 Stolen Power Package 112 Attention Required after Submersion 112 Replacement Service Parts 112 Parts and Accessories Inquiries 113 Res...

Page 120: ...t an authorized Mercury MerCruiser dealer 2 After recovery immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage Replacement Servi...

Page 121: ...the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact...

Page 122: ...ed States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or con...

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